Electrodepositable battery electrode coating compositions having coated active particles

Abstract

The present invention is directed towards an electrodepositable coating composition comprising an electrochemically active material comprising a protective coating; an electrodepositable binder; and an aqueous medium. Also disclosed herein is a method of coating a substrate, as well as coated substrates and electrical storage devices.

1 . An electrodepositable coating composition comprising:
 an electrochemically active material comprising a protective coating;   an electrodepositable binder; and   an aqueous medium.   
     
     
         2 . The electrodepositable coating composition of  claim 1 , wherein the protective coating comprises a metal compound or complex. 
     
     
         3 . The electrodepositable coating composition of  claim 2 , wherein the metal compound or complex comprises (i) a metal chalcogen; (ii) a metal pnictogen; (iii) a metal halide; (iv) a metal oxyhalide; (v) a metal oxynitride; (vi) a metal phosphate; (vi) a metal carbide; (vii) a metal oxycarbide; (viii) a metal carbonitride; (ix) an olivine; (x) a NaSICON structure; (xi) a polymetallic ionic structure; (xii) a metal organic structure or complex; (xiii) a polymetallic organic structure or complex; or (xiv) a metal carbon-based coating. 
     
     
         4 . The electrodepositable coating composition of  claim 1 , wherein the protective coating comprises a metal-oxide coating. 
     
     
         5 . The electrodepositable coating composition of  claim 4 , wherein the metal-oxide of the metal-oxide coating comprises an oxide of titanium. 
     
     
         6 . The electrodepositable coating composition of  claim 5 , wherein the oxide of titanium comprises titania. 
     
     
         7 . The electrodepositable coating composition of  claim 4 , wherein the metal-oxide of the metal-oxide coating comprises an oxide of aluminum. 
     
     
         8 . The electrodepositable coating composition of  claim 7 , wherein the oxide of aluminum comprises alumina. 
     
     
         9 . The electrodepositable coating composition of  claim 4 , wherein the metal-oxide coating comprises silica. 
     
     
         10 . The electrodepositable coating composition of  claim 4 , wherein the metal-oxide coating comprises zirconia. 
     
     
         11 . The electrodepositable coating composition of  claim 1 , wherein the protective coating comprises a carbon-based coating. 
     
     
         12 . The electrodepositable coating composition of  claim 11 , wherein the carbon-based coating comprises a metal carbonate. 
     
     
         13 . The electrodepositable coating composition of  claim 12 , wherein the carbon-based coating comprises lithium carbonate. 
     
     
         14 . The electrodepositable coating composition of  claim 1 , wherein the protective coating comprises a non-metal compound or complex. 
     
     
         15 . The electrodepositable coating composition of  claim 14 , wherein the non-metal compound or complex comprises (i) a non-metal oxide; (ii) a non-metal nitride; (iii) a non-metal carbonitride; (iv) a non-metal fluoride; (v) a non-metallic organic structures or complexes; (vi) or a non-metal oxyfluoride. 
     
     
         16 . The electrodepositable coating composition of  claim 1 , wherein the electrochemically active material comprises a material capable of incorporating lithium, and the material capable of incorporating lithium comprises LiCoO 2 , LiNiO 2 , LiFePO 4 , LiCoPO 4 , LiMnO 2 , LiMn 2 O 4 , Li(NiMnCo)O 2 , Li(NiCoAl)O 2 , carbon-coated LiFePO 4 , or a combination thereof. 
     
     
         17 . The electrodepositable coating composition of  claim 1 , wherein the electrochemically active material comprises a material capable of lithium conversion, and the material capable of lithium conversion comprises sulfur, LiO 2 , FeF 2  and FeF 3 , Si, aluminum, tin, SnCo, Fe 3 O 4 , or combinations thereof. 
     
     
         18 . The electrodepositable coating composition of  claim 1 , wherein the electrodepositable binder comprises a fluoropolymer. 
     
     
         19 . The electrodepositable coating composition of  claim 18 , wherein the electrodepositable binder further comprises a dispersant. 
     
     
         20 . The electrodepositable coating composition of  claim 1 , wherein the electrodepositable binder comprises a pH-dependent rheology modifier. 
     
     
         21 . The electrodepositable coating composition of  claim 20 , wherein the pH-dependent rheology modifier comprises an alkali-swellable rheology modifier. 
     
     
         22 . The electrodepositable coating composition of  claim 20 , wherein the pH-dependent rheology modifier comprises an acid-swellable rheology modifier. 
     
     
         23 . The electrodepositable coating composition of  claim 20 , further comprising a curing agent. 
     
     
         24 . The electrodepositable coating composition of  claim 1 , wherein the electrodepositable binder comprises an ionic, film-forming resin. 
     
     
         25 . A method of coating a substrate, the method comprising:
 electrophoretically depositing the electrodepositable coating composition of  claim 1  onto a substrate.   
     
     
         26 . A coated substrate comprising an electrical current collector and a coating formed on the at least a portion of the electrical current collector, wherein the coating is deposited from the electrodepositable coating composition of  claim 1 . 
     
     
         27 . The coated substrate of  claim 26 , wherein the electrical current collector comprises aluminum, copper, steel, stainless steel, nickel, conductive carbon, a conductive primer coating, or an electrically conductive porous polymer. 
     
     
         28 . The coated substrate of  claim 26 , wherein the coated substrate comprises a positive electrode. 
     
     
         29 . The coated substrate of  claim 26 , wherein the coated substrate comprises a negative electrode. 
     
     
         30 . The coated substrate of  claim 26 , wherein the electrical current collector is pretreated with a pretreatment composition. 
     
     
         31 . An electrical storage device comprising:
 (a) an electrode comprising the coated substrate of  claim 26 ;   (b) a counter-electrode, and   (c) an electrolyte.   
     
     
         32 . The electrical storage device of  claim 31 , wherein the electrical storage device comprises a cell, a battery, a battery pack, a secondary battery, a capacitor, a supercapacitor, and/or a pseudocapacitor. 
     
     
         33 - 37 . (canceled)